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I'm just a novice, but I have done several heads on a variety of cars.
It's not that unusual for a car that has overheated badly once, to continue to have problems.
Most probably the first bad overheating could have caused the head to warp slightly. Since it's aluminum and the block is iron, the two expand at different rates. After the initial problem, the car might run okay, but as the engine heats up, there could be a slight gap, loosing pressure in the coolant system. Since the system is designed to be closed, and under pressure, the loss of pressure causes the coolant boiling point to go down. i.e. you overheat at a lower temp.
This continual overheating just gets worse as you go along, so.... cracked head,
etc.
The first head gasket replacement might not have included milling the head.
You should be able to find a competent machine shop to redo your head for about 200-300. Then the labor on a B230f engine should not be too bad, it's really a simple job. The hardest part is getting the crank pulley off!
If it's a b234f engine, like mine, the cost would be higher, I was quoted
$3-4,000 by a local independent, and I did it myself for about $900.00.
This included replacing 10 bent valves, new valve seals, and milling the head, though which should not be a problem in your case.
good luck,
jc
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1985 740gle na, 1990 740gle 16 valve
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